System and method of foamed cementitious construction

ABSTRACT

A building system and method. A construction method and system is disclosed. The system includes panel members composed of foamed cement containing perlite as the only material aggregate. Each lightweight cement body is encased around its perimeter edges by a rigid frame preferably fabricated from steel C-channel or beams. Once cured, a plurality of such panels vertically disposed, arranged upon building footings, and inter-connected to serve as structure walls. The use of a special foamed cementitious mix containing expanded perlite provides lightweight panels of reliable strength and durability yet excellent thermal and sound insulation. The frames of abutting panels may be joined by welding. Reinforced concrete footings according to this disclosure are provided with a special channel running longitudinally there-along. An exposed anchor bar runs along the inside of the longitudinal channel. The wall panels have reinforcing conduits extending top to bottom in the panel frame. Tie rods situated in the conduit interiors extend beyond the conduit ends. The upper end of each tie rod is adjustably engaged with the end of the corresponding conduit, while the tie rod lower end is connected to the anchor rod on the footing. With the tie rod attached to the footing&#39;s anchor rod, the controlled tightening of the engagement of the tie rod and conduit upper ends pulls the tie rod into tension to secure the panel to the footing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing of U.S. ProvisionalPatent Application Ser. No. 60/718,409 entitled “Foamed CementitiousBuilding Material and Method of Use,” filed on Sep. 16, 2005, and thespecification thereof is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention (Technical Field)

The present invention relates to construction methods and materials,generally to methods and materials for constructing building structures,particularly concrete construction, and specifically to a cementitiouscomposition and method of using it to erect structures.

2. Background Art

It has been known for centuries that structural elements may befashioned from cement, and reinforced concrete has been used instructural design and erection for nearly a century. Modern concretestructures typically are reinforced with steel rods (“rebar”), and theconcrete mix includes Portland cement, sand, and aggregates.

Reinforced concrete structural elements pose certain challenges anddisadvantages. Two leading challenges are the comparatively heavy weight(vis-a-vis lumber post and beam construction) and thermal conductivity.The weight of concrete, both while wet and when cured, demands carefulplanning and operation during the placement of the mix, as well asdesign considerations to provide for a self-supporting structure thatalso can withstand further active loading. Concrete, especially denseand heavily reinforced concrete, also is a less than optimal thermalinsulator; in cold climates, concrete walls and floors can serve toconduct heat from a building interior to the ground and outdoor air.

There is known in the art of concrete construction generally the use offoaming agents to affect the material characteristics of concrete. Thefollowing patents, the disclosures of which are incorporated herein byreference, offer background information regarding the preparation offoamed concrete compositions:

U.S. Pat. No. 4,057,608 to Hashimoto, et al.;

U.S. Pat. No. 4,268,558 to Boardman;

U.S. Pat. No. 4,270,329 to Moore;

U.S. Pat. No. 4,373,955 to Bouchard, et al.;

U.S. Pat. No. 4,419,134 to Ishijima, et al.;

U.S. Pat. No. 4,789,244 to Dunton, et al.;

U.S. Pat. No. 4,872,913 to Dunton, et al.;

U.S. Pat. No. 5,413,633 to Cook, et al.;

U.S. Pat. No. 5,596,860 to Hacker;

U.S. Pat. No. 5,605,570 to Bean, et al.;

U.S. Pat. No. 5,795,060 to Stephens;

U.S. Pat. No. 6,046,255 to Gray, et al.;

U.S. Pat. No. 6,210,476 to Chatterji, et al.;

U.S. Pat. No. 6,153,005 to Welker, et al.;

U.S. Pat. No. 6,833,091 to Johansson, et al.; and

U.S. Patent Publication No. 2005/0133221 to Chatterji, et al.

SUMMARY OF THE INVENTION

A construction method and system is disclosed. The system includes panelmembers composed of foamed cement containing perlite as the onlymaterial aggregate. Each lightweight cement body is encased around itsperimeter edges by a rigid frame preferably fabricated from steelC-channel or beams. Once cured, a plurality of such panels verticallydisposed, arranged upon building footings, and inter-connected to serveas structure walls. The use of a special foamed cementitious mixcontaining expanded perlite provides lightweight panels of reliablestrength and durability yet excellent thermal and sound insulation. Theframes of abutting panels may be joined by welding.

Reinforced concrete footings according to this disclosure are providedwith a special channel running longitudinally there-along. An exposedanchor bar runs along the inside of the longitudinal channel.

The wall panels have reinforcing conduits extending top to bottom in thepanel frame. Tie rods situated in the conduit interiors extend beyondthe conduit ends. The upper end of each tie rod is adjustably engagedwith the end of the corresponding conduit, while the tie rod lower endis connected to the anchor rod on the footing. With the tie rod attachedto the footing's anchor rod, the controlled tightening of the engagementof the tie rod and conduit upper ends pulls the tie rod into tension tosecure the panel to the footing.

Roof decking is placed upon and secured to the plurality of erected wallpanel members. Wet concrete is then placed, in a monolithic pour, downthe reinforcing conduits and into the footing's longitudinal channel tofill the channel, fill the conduits, and to cover the roof deck to adesign depth. This singular pour, besides providing a concrete roof capand a bond beam along the tops of the panels, integrates the roof withthe footing by bonding the tie rods and conduits to the roof andfooting.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated into and form a partof the specification and, together with the description, serve toexplain the principles of the invention. The drawings, all views andportions of which are not necessarily to uniform or consistent scale,are only for the purpose of illustrating a preferred embodiment of theinvention and are not to be construed as limiting the invention. In thedrawings:

FIG. 1 is an exploded top perspective view of a basic panel member andfooting segment according to the present disclosure, with dasheddirectional lines indicating the placement of the panel upon thefooting. Portions of the cementitious panel body, which in a completeinstallation extend the full length of the panel member, are broken awayto permit illustration of panel frame elements.

FIG. 2 is an enlarged top perspective view of an upper outside cornershowing the welded juncture of two wall panel members according to thepresent disclosure.

FIG. 3 is an exploded side perspective view of segments of top andbottom panel frame members, and a portion of a footing, according tothis disclosure. A portion of the footing is broken away to illustratethe provision of an anchor rod, and means for anchoring the anchor rodto the footing, within the footing's longitudinal top channel. Majorportions of an associated panel member are omitted from the view forclarity of illustration. The upper ends of a conduit and a tie rod areassociated with the top frame member, and the lower ends of the sameconduit and tie rod are associated with the bottom frame member, and thedashed directional lines suggest the positional relationships of theframe, tie rod and conduit members, and their installation upon thefooting and the hooked engagement of the tie rod with an anchor bar inthe footing.

FIG. 4 is an enlarged schematic end view of an upper portion of a panelmember according to this disclosure.

FIG. 5 is a sectional end view of a panel member according to thepresent disclosure, showing its conjuncture with a roof.

FIG. 6 is an enlarged partially sectional end view of a lower portion ofa panel member, shown connected to a portion of a footing by means of ahooked engagement between a tie rod in the panel member and an anchorbar in the footing.

FIG. 7 is a multiply exploded side schematic view of two stacked panelmembers according to the present disclosure, illustrating how theinventive system may be modified for utility in a two-story structure.

FIG. 8 is a perspective and partially sectional view of two panelmembers according to the present disclosure placed end-to-end andinstalled upon a footing. A roof is shown in section, with a portionbroken away to reveal a section of a panel frame and the roof deck.

FIG. 9 is an end sectional view of two panel members stacked verticallyin the erection of a two-story building.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Best Modes for Carrying Out theInvention

There is disclosed hereby a construction system and methods for erectingstructures, especially including but not limited to residentialdwellings of either single- or multiple-family types. The information ofthe present disclosure is most readily understood in the context ofconstructing a single-family home; however, it is to be understood thatthe principles and teachings hereof may be adapted to the erection ofnearly any type of building, including commercial and industrialstructures. Teachings are offered for a system and method ofconstruction. A lightweight foamed cementitious composition also isdisclosed from which structural elements may be fabricated.

The building system and method of erection employ a somewhat modularapproach, whereby a plurality of panel components are fabricated andthen assembled at the building site. Fundamental panel components arefabricated, either on- or off-site, for subsequent installation uponspecially devised footings. The panel components may be constructed in awide variety of sizes and shapes for use in and at different locationswithin a structure, to fulfill identified particular structural needs,or to accommodate architectural aesthetics as well as building systems(plumbing, electrical, heating, ventilation, air conditioning, etc.)function.

Accordingly, the depiction and description of particular panelcomponents herein is not intended to be limiting as to the specificshape or size of panels, but rather to typify panel components withinthe ambit of the present invention. The construction of a buildingaccording to the present disclosure may involve the fabrication of manypanel components, with no two panels being the same in size and form. Asmentioned, a plurality of differing panels according to the inventionare fabricated and assembled to erect a building, whether small andsimple or large and complex. The versatility of this system andmethodology permit the design and construction of any of a nearlylimitless variety of building types and sizes.

A panel member according to the present disclosure has a body incasedwithin a rigid framework. Each panel features a frame that defines theperimeter—the top, two ends, and bottom—of the panel. Panels areassembled and interconnected to constitute the main structural elements,most generally the vertical walls, of the building. The volume withineach frame is occupied by a poured and cured foamed cementitiousmaterial that defines the body of the panel. The body of the paneltypically has two parallel sides or faces, corresponding to the exteriorand exterior sides of a wall, which sides are separated by a dimensioncorresponding to the panel thickness (which in turn serves as the basisfor the thickness of the wall).

A panel framework features a frame preferably constructed from steelelements, but the frame alternatively may include elements of woodand/or synthetics, including wood-plastic composites. A panel's framedefines its shape and overall size, including thickness. The frameencases the cementitious panel body along its perimeter, while the broadfaces of the body are exposed (e.g., for further covering or finishing,as with stucco, brick, siding, etc., on the exterior, and gypsum board,decorative paneling, or the like on the interior). An advantage of theinvention is the low thermal conductivity of the panel body, althoughthe invention may be practiced in a manner permitting installation ofadditional insulating materials on either face of the panel body.

The cementitious panel body is poured within a formwork including theframe (i.e., with the framework disposed horizontally upon the groundand allowed to cure. The material of the panel body is a foamed,perlite-containing cement, described further hereinafter.

The structural integrity of each panel is provided primarily by theframe, which in the preferred embodiment is constructed of 8-25 gaugesteel C-channel. Each panel also features at least one, and preferablytwo or more, internal conduit reinforcements. The internal conduitspreferably are 8-25 gauge steel pipe, preferably of at least 2-inchdiameter, and more preferably between about 3 inches and 5 inches indiameter. The reinforcing conduits are disposed parallel to the ends ofthe panel, such that when a panel is vertically oriented upon a footing,the reinforcing conduits are parallel at a minimum of 24-inch on-centerspacing along the horizontal extent of the panel. The upper end of eachreinforcing conduit intersects with, and in the preferred embodiment iswelded to, the top element of the frame; likewise the lower end of aconduit is secured to the bottom element of the frame.

In construction, individual panels are placed end-to-end to constitutebuilding walls and corners. In the preferred embodiment, the end of eachpanel is defined by a vertically disposed length of steel C-channel.Accordingly, the ends of adjacent panels contact one anther, andpreferably are welded (e.g., stitch welded) along vertical corners(exterior and interior). Further, a top weld preferably is installedalong the “seam” defined by the tops of the abutting panels.

In a preferred embodiment, each panel is secured to its footing by meansof tie rods situated within and extending beyond both ends of, thereinforcing conduits. The footing is provided with a horizontal anchorbar exposed within a longitudinal channel in the top of the footing. Thebottom end of the tie rod is attached to the anchor bar, as by a hookmeans (on the end of the tie rod) engagable practically anywhere alongthe anchor bar. The top end of the tie rod is engaged with the upper endof the reinforcing conduit. This engagement preferably is accomplishedby means of a rigid strap bracket disposed across the conduit upper end,and having a central aperture through which the tie rod is passed. Thetop end of the tie rod is threaded, and a tie nut is screwed down thetie rod until the nut contacts the strap bracket; thereafter, continuedrotation of the tie nut tightens the nut to press down on the strapbracket while also drawing the tie rod into tension between the strapbracket and the anchor bar. Tightening the tie nut against the strapbracket secures the panel to the footing, via the connection provided bythe tie rod extending between the footing's anchor bar and the strapbracket on the top end of the reinforcing conduit.

Upon the completion of panel installation to provide the structure'svertical walls, a roof is placed. The system utilizes commerciallyavailable lightweight polystyrene roof deck product that is disposedupon the tops of the vertical panels to provide a form and support for areinforced poured concrete roof. This roof deck spans between supportingwalls, and is secured to the wall tops. The roof, wall panels, andfooting are then set by a monolithic concrete pour. The pour fills thechannel in the footing (and thus encases the anchor bar), also fills thereinforcing conduits (thus surrounding the tie rods), and then coversthe polystyrene roof deck to the desired depth to define the roof panel.This monolithic pour is permitted to cure without cold joints, thusintegrating the roof, walls, and footings to provide an extremelystrong, thermally insulated building shell.

Reference now is made to FIG. 1, showing generally, but by basicillustration, the practice of the apparatus and method. A reinforcedconcrete footing 20 is provided upon the ground. A prefabricated panelmember 30 is then placed upon the top of the footing, as indicated bythe dashed directional lines of the exploded view of FIG. 1.

Referring both to FIG. 1 and FIG. 8, the footing 20 is constructedgenerally according to known and accepted principles of reinforcedconcrete design and engineering, except as otherwise explained herein. Alongitudinal channel 22 is defined along the entire length, or at leasta substantial length, of each footing 20 in the top surface thereof. Asseen in FIG. 1, the longitudinal channel 22 preferably but notnecessarily is centrally located on the top of the footing 20, generallyparallel to the footing's sides. The longitudinal channel 22 may becreated or defined by laying a metal C-channel 23 (FIG. 6), legs andopen side facing up, in the top surface of the footing 20 after pouringbut before curing the footing.

Referring to FIGS. 3, 5, 7, and especially 6, it is seen that thepreferred form of footing 20 includes an exposed anchor bar 24 withinand along the longitudinal channel 22. The anchor bar 24, which may besteel rebar, is disposed in the channel in a position spaced-apart fromthe channel walls and bottom. As particularly suggested in FIGS. 3 and6, the anchor bar 24 is intermittently but well anchored to the footing20. Any of a variety of means for anchoring the anchor bar to thefooting 20 may be used. In one preferred embodiment, a plurality ofsecuring eye-bolts 25 are integrated with the footing 20, so to havetheir eyes aligned approximately along the axis of the longitudinalchannel 22. Alternative to the use of closed-eye bolts, open-hook boltsmay be used to facilitate easy engagement of the length of anchor bar 24with the plurality of linearly aligned bolts 25. Other means foranchoring the anchor bar 24 to the footing 20 may be used withoutdeparting from the scope of this invention. FIGS. 3 and 6 show how theeyebolts 25 or other anchoring means may extend into the volume of thelongitudinal channel 22, either from the sides of the bottom of thechannel 22, and preferably are placed or shortly after the footing 20 ispoured. The anchor bar 24 thus may be secured by integrating with thefooting 20 a securing bolt 25 that extends into the longitudinal channel22, and then threading or hooking the bar 24 through the exposedbusiness end of the securing bolt 25. Furthermore, each end of thehorizontally disposed anchor bar 24 preferably extends into the footing22, e.g., is bent abruptly to extend into the bottom of the channel 22before the footing solidifies.

Combined reference is made particularly to FIGS. 1 and 8. A panel member30 has two main features, the frame 32 and the panel body 40. Assemblinga frame 32 ordinarily involves assembling elements to define at least atop 34, two ends 36, and a bottom 38 of the panel 30. Door and windowsub-frames, not shown in the figures for simplicity of illustration, maybe assembled and attached within the main panel frame 32, and theirprovision is within ordinary skill in the art. In a preferredembodiment, the frame has a plurality (e.g., four) of rectilinearmembers 34, 36, 38 contiguously interconnected to define a generallyrectangular frame 30 as seen in FIG. 1. The rectilinear membersproviding the top 34, two ends 36, and bottom 38 preferably are segmentsof steel C-channel cut to the selected design lengths. The segments ofC-channel defining the frame 32 are arranged and disposed such that the“legs” of the C-channel face “inward” toward the center of the(typically rectangular or square) panel member 30. The joints whereatadjacent and adjoining frame members 34, 36, 38 abut are permanentlyconnected by welding according to convention.

Frames of panel members according to the invention are arranged andconfigured according to the particular structure design plan; anadvantage is that adjoining panel frames may be welded to significantlypromote structural integrity. For example, FIG. 2 shows the top outsidecorner of two conjoined panel members according to this disclosure,having abutting respective frames 32, 32′. The C-channel end 36 of onepanel frame 32 contacts the C-channel end 36′ of the other frame 32,while the corresponding frame tops 34, 34′ also are in contact. A longweld 71 is placed along the joint between the panel tops 34, 34′. Alongthe exterior seam of a corner, the two frame ends 36, 36′ are in contactfor their complete common length (e.g., the height of a panel member).Accordingly, stitch welds 70, placed intermittently along the junctureof the ends 36, 36′ are adequate. Welded connections among thecontiguous panel frames of a building provides for an overall structuralsystem of tremendous strength and load-bearing capability.

FIG. 8 shows two panel members 30 placed end-to-end upon a footing 20,and conjoined in a manner according to the present invention.

Reference is made to FIGS. 1, 3, and 5. At least one, preferably more,hollow reinforcing conduits 42 are situated within the frame 32. Eachconduit extends from an upper conduit end 43 penetrating the top 34 ofthe frame 32 to a lower conduit end 44 penetrating the bottom 38 of theframe 32 to provide fluid communication between the top 34 and bottom 38of the frame. The conduit 42 may be cylindrical, or have any otherradial cross-sectional shape, but is composed of a strong, rigidmaterial resistant to both bending and axially compressive loading. Theconduits 42 preferably are design lengths of steel pipe; situating anyparticular conduit 42 in the frame preferably involves the welding thesteel pipe to at least the top steel C-channel member 34. Verypreferably, the upper conduit end 43 is welded to the steel top 34 andthe lower conduit end 44 likewise is welded to the steel C-channelbottom 38.

Notably, and as seen in the drawing figures, especially FIGS. 3 and 4,the upper conduit end 43 may extend above the top 34 a short distance(e.g., about six inches). The lower conduit end 43, however, whilepenetrating the bottom 38 does not extend beyond the bottom but is flushtherewith so that the bottom of the frame 32 may rest in flush contactupon the top surface of the footing 20.

The foamed cementitious panel body 40 is formed within the frame 32; thepanel body 40 has two sides (e.g. an exterior face and an interior face,typically both planar), with the frame defining the overall perimeterand thickness of the body (FIGS. 1 and 5). During erection of adwelling, an assembled frame 32 may be laid horizontally upon theground, with a planar form beneath to delimit an exterior side of thepanel body to be poured. The wet foamed cementitious material may thenbe poured into the molding form thus provided, stricken and floated flaton its upper surface to define an “interior” side of the body 40, andallowed to cure. After the material of the body panel 40 has adequatelycured, and thus is a lightweight solid, the entire panel member 30 maybe moved to storage, transported to the job site, etc. With thecomposition of the body 40 cured, the panel member 30 can withstandstresses associated with being shipped and manipulated about, includingbeing placed in a vertical orientation upon a suitable footing 20.

The cementitious mixture for the panel body 40 preferably is preparedand poured into a frame 32 at a central manufacturing facility. Thecured panels may then later be transported to various jobsites asneeded. Alternatively but less desirably, the panel body 40 may bepoured and cured at the building construction site.

The panel body's cementitious mix includes as main ingredients Portlandcement, foaming agent, expanded perlite, and water. To prepare one cubicyard of wet mix, the dry ingredients are mixed in the following ranges:

Portland cement: about 325 lbs to about 950 lbs, preferably between 450lbs and 600 lbs, and most preferably about 540 lbs (to make about 1.0yd³wet mix).

Expanded perlite: about 3 lbs to about 270 lbs, preferably between 20lbs and 100 lbs, and most preferably about 50 lbs (to make about 1.0 yd³wet mix).

The dry ingredients are mixed with water at a water/cement ratio ofapproximately 0.5, to which wet mix the foaming agent is added. Foamingagents may be either synthetic or organic; a very suitable agent isavailable commercially from Cellular Concrete, LLC of Allentown, Pa.,USA, under the trademark MEARLCRETE. Foam liquid concentrate is added tothe mix at rates of between approximately 1.5 and 2.0 lbs per cubic yardof wet mix, which typically yields a foam volume of between about 16ft³/yd³ and about 21 ft³/yd³. The foregoing material measures andweights are recited for a single cubic yard, approximately, of cellularconcrete. Persons skilled in the art know to multiply amounts by anumber corresponding to the total number of cubic yards required in agiven batch of wet mix.

Further, it is contemplated that newer “catalyzed” foaming agents may beused in the disclosed system and method. Catalyzed agents result inrapid setting of the cellular foam to maintain a lightweight pour whilethe concrete cures (which also may contain admixtures to acceleratecuring). Catalyzed foam liquid products are available from Allied FoamTech Corporation, Montgomeryville, Pa., USA.

The resulting wet batch is well-mixed to activate the foaming agent, andthen quickly poured and finished, as with floating and screeds known inthe art of concrete construction. Once poured to design thickness withina formed frame 32, the foamed cementitious mix is allowed to cure;adequate curing, at ambient temperatures (preferably above 70° F.) andhumidity, to permit panel transportation to a job site, typicallyrequires about four days. However, if catalyzed foaming agents andaccelerating admixtures are included in the mix, curing times can bereduced to as little as twelve hours.

The cementitious mix according to this disclosure cures to have a drydensity of less than approximately 44 lbs/ft³ , and a thermalconductivity believed to be less than about 1.0 Btu in/hr per squarefoot per degree Fahrenheit.

Referring to FIGS. 1, 3, 7, and 8, and as best seen perhaps in FIG. 4, arigid frame flange 55 is attached along the outside length of a frametop 34 by welding, bolting or any other suitable means. The frame flange55 serves as a form for a poured bond beam 68 (FIG. 5) and roof 60, tobe further described hereinafter. A frame flange 55 preferably but notnecessarily is composed of the same or similar steel gauge as comprisesthe frame members 34, 36, 38. The frame flange 55 projectsperpendicularly (for example, about 12 inches) from the frame top 34,and is secured thereto along one edge (i.e. an “outside” edge) asindicated in the drawing figures. There preferably are provided aplurality of gussets 56 at spaced intervals along the top 34, situatedorthogonally to both the top 34 and the frame flange 55, to reinforcethe connection between frame flange and top, and to contributestructural integrity to the overall panel member 30. A gusset 56 may bepenetrated, as needed, with a pour aperture 57 (FIG. 1) to permit wetcement to flow through from one side of the gusset to the other.

Optionally but often, electrical conduit 75 and switch boxes 73 (FIG. 1)generally according to known art are incorporated within a frame 32prior to the pouring of the cementitious panel body 40 therein. Wiringis pulled through the conduits 75 as a cured panel member 30 is set inplace upon a footing 20. Wiring also ordinarily is pulled before thepouring of the roof cap and upper bond beam on the frame, as describedfurther herein. Certain plumbing stubs and conduits likewise may beblocked out or pre-installed within a frame 32 prior to the pouring ofthe panel body 40 there around.

Attention is invited to FIGS. 3, 6 and 7. Further erection of astructure according to this disclosure includes the placement of a curedpanel member 30 upon the footing 20. Placing the panel member 30 uponthe footing 20 includes registering the panel member bottom 38 with thelongitudinal channel 22 while also placing the lower conduit end 44 influid communication with the channel 22.

The frame bottom 38 is placed in flush contact with the top of thefooting 20, laterally spanning the longitudinal channel 22. The panelmember 30 thus is aligned with the longitudinal channel; panel bottom 38is in registration with the channel and proximate to (and roughlyparallel to) the anchor bar 24. The panel member 30 then is attached tothe footing 20 by securing the panel member 30 to the anchor bar 24.

Referring to FIGS. 3 and 7, it is seen that securing the panel member 20to the anchor bar 24 includes situating a tie rod means 46 along theinterior length of each reinforcing conduit 42, connecting the lower endof each tie rod 46 to the anchor bar 24, and engaging the upper end ofeach tie rod with the upper end of the conduit 42. Each conduit 42 of aparticular panel member 30 has a tie rod 46 therein; each tie rod has aneffective length exceeding the length of its surrounding conduit, sothat the tie rod upper end 48 extends (e.g., a few inches) beyond theconduit upper end 43, and also extends (e.g. several inches) below thepanel frame bottom 38.

As best seen in FIG. 6, the lower end 47 of the tie rod 46 features oris provided with a connecting means, such as a hook 49, for connectingthe lower end 47 of the tie rod to the anchor bar 24. The lower end 47,bearing the hook connector 49, extends from the lower end 44 of theconduit 42 thus to project below the bottom 38 of the frame. By engagingaround the anchor bar 24 all the hook means 49 associated with a givenpanel member, the panel member can be secured to the footing.

The upper end of the tie rod 46 is engaged to the upper end of theconduit 42. One means for realizing this engagement is shown in FIGS. 3and 4. There it is seen that the projecting portion of tie rod upper end48 is threaded to receive a complementarily threaded locking nut 50. Foreach and every conduit and tie rod, 42, 46, there is provided a rigidstrap bracket 51. The length of the bracket 51 exceeds the diameter ofthe conduit 42. The metal alloy planar strap bracket 51 has a centralaperture 52 through which is passed the threaded upper end 48 of the tierod 46. Upon placement around the tie rod 46, the strap bracket 51 isthen disposed across the conduit upper end 43 in contact therewith.Notably, the short-dimension width of the bracket 51 is considerablyless than the diameter of the conduit 42, so that wet concrete may flowpast the installed strap bracket and into the open upper end 43 of theconduit, thereby to permit the conduit to be filled with concrete.Preferably, concrete can flow freely through the conduit 42 in eitherdirection, as both the upper and lower ends 43, 44 thereof are open(FIG. 3). Screwed tightening of a locking nut 50 against the strapbracket 51, while the connector 49 is engaged with the anchor bar 24,draws the tie rod 46 into tension; continued tightening of all thelocking nuts arranged along a given panel member 30 pulls the panelmember into extremely reliable and secure connection to its underlyingfooting 20.

A noteworthy benefit and significant advantage of the present system isthe versatility of the afore-described mode of connecting a panel memberto its associated footing. Because the anchor bar 24 is exposed andavailable along a major portion, or the entirety, of the length of thefooting 20, there is little difficulty aligning each hook connector 49with the anchor bar for engagement therewith. Without regard for thenumber or spacing of the conduits 42 (and thus the tie rods 46) in aparticular panel member 30, the anchor bar is available directly belowthe lower end 47 of each tie rod 46. The step of engaging the hook means49 around the anchor bar 24 thus beneficially involves engaging the hookat substantially any location along the full length of the anchor bar24. This provides tremendous flexibility and facility in locating panelmembers 30 along a footing 20 for proper installation. In sum, thesystem's anchor bar running axially along the footings permitsconstruction workers to position the panel members on the footingsaccording to design plan, but with minimal concern for assuring theavailability of an anchor point aligned directly below each hookconnector 49.

The system also includes the placement of a roof 60 atop a collection oferected panel members 30. Referring to FIGS. 5 and 8, the preferred roofinstallation involves the disposition of a reinforced plastic deck 62upon the tops 34 of erected panel members, so as to span frompanel-to-panel, i.e., from wall to wall, according to the configurationof the particular structure. A lightweight cement is then poured andapproximately leveled (or pitched to provide drainage, per specificdesign) onto the roof deck 62, so that, after the cement cures, adurable, generally planar cement roof cap 63 is the exposed uppersurface of the roof 60.

Roof deck 62 is any of a number of products available commercially“off-the-shelf,” which are devised to be the reinforced substrata andsupporting form for suspended pours of lightweight layers of concrete.Such concrete roof decking products include the LITE-DECK productavailable through Lite-Form International of South Sioux City, Neb.,USA; or the QUAD-DECK product available from Quad-Lock Building SystemsLtd. of Surrey, British Columbia, Canada. Such products generally arefabricated from reinforced polystyrene, and are engineered to supportand form poured concrete roofs (and floors in upper stories ofmulti-storied structures). A deck 62 according to this disclosure isreinforced both by its design moment of inertia as well as metal stripsand cables integrated within the plastic deck. Further, an upper surfaceof the deck 62 preferably features a plurality of parallel longitudinaltroughs or channels into which reinforcing rods may be placed. Suchtroughs may have a “dove-tail” shape, such that wet concrete flowsthrough a narrower upper neck and into a broader lower volume, therebysecurely integrating the deck 62 with a concrete cap 63 pouredthereupon.

Referring particularly to FIGS. 5 and 7, it is seen that an end of adeck 62 is lowered upon an inside portion of the upper surface of theframe top 34, and there secured by bolting or other known means. In thepreferred embodiment, the lateral width of the top 34 (i.e., thethickness of the panel member 30) and the diameter of the reinforcingconduit 42 are such that the end of the deck 62 can abut the upper endsof the conduits 42 projecting above the frame top 34, and yetsubstantially overlap the frame top to rest thereupon. By way ofnon-limiting example, if the frame top 34 is one foot wide and theconduits 42 along the axis of the top 34 each have a diameter of fourinches, the flush overlap of the bottom of the deck 62 upon the frametop 34 is approximately four inches. This secured overlapping connectionof deck 62 to frame top 34 is best seen in FIG. 7.

With adequate decking 62 installed upon a plurality of verticallyoriented panel members configured according to design, a roof cap 63 maybe placed. A final one of the principal steps and components of themethod and system is the pouring of wet concrete to fabricate the roofcap 63, which pour is simultaneous to the pouring of concrete into thereinforcing conduits 42 and the longitudinal channel 22 in the footing.Such a monolithic pour serves to securely interconnect further thevarious modules of the structure, as the curing concrete bonds not onlywith the roof deck 62, but also the interior of the reinforcing conduits42, the surfaces of the tie rods 46, the anchor bar 24, and the footing20. Further, as the concrete fills the volume above the frame top 34 andbetween the end of the deck 62 and the frame flange 55, a concrete upper“bond beam” 68 is created along the frame top 34.

The wet concrete mix is poured (or pumped, as needed) atop the structureand onto the roof deck 62. Pouring continues for sufficient time andvolume to cover the entire deck 62 to the design depth; the thickness ofthe concrete roof cap 63 may be determined by the elevation of the topedge of the frame flange, as suggested in FIG. 5.

As wet concrete is poured onto the deck 62, it also is poured into theopen upper ends 43 of the conduits 42. Flowing down through eachconduit, the wet mix discharges from the lower ends 44 of the conduits,which are adjacent to and in fluid communication with the associatedfootings' respective longitudinal channels 22. The mix accordingly flowsby gravity into, along, and through the channels 22 until the channelsare filled and the anchor bars 24 are surrounded and encased with wetconcrete. Further, the points of engagement between the hooks or otherconnector means 49 and the anchor bars 24 likewise are fully submerged.Each concrete-filled longitudinal channel 22 thus serves, after cure, asa sort of bottom bond-beam for a panel member 30 directly above.

After the longitudinal channels are full of concrete mix, pouringcontinues to fill each conduit 42 with concrete. The conduits 42 fill,surrounding the tie rods 46 with wet mix. Once all the conduits arefull, the pouring continues to fill to the design elevation of the topof the roof cap 63. A volume above the top 34 of each panel member, anddefined between the frame flange 55 and the roof deck 62 fills withconcrete to provide, when cured, an upper bond beam 68 integrated withthe roof cap 63. Pouring is not interrupted until all the decks 62 arecovered to the design depth to provide a layer of concrete defining theroof cap 63 when cured. Notably, the monolithic pour means that theconcrete extends from footing 20 to roof cap 63 via the reinforcingconduits 42 without any undesirable intermediate “cold joints.” FIG. 5shows that the monolithically poured concrete 64 fills each reinforcingconduit 42 and the channel 22 there below, and extends from the top ofthe conduit to be integral with the concrete upper bond beam 68 and roofcap 63.

Dimensions and specifications for a system according to this disclosureare subject to design engineering according to principles known in theart. However, some illustrative dimensions may be offered by way ofexample, rather than illustration.

Panel members 30 defining exterior walls are fabricated to a preferredminimum thickness of six inches, and more preferably from between abouttwelve inches and about twenty-four inches thick. Panel members 30serving as interior and/or non-weight-bearing walls may be fabricated toa thickness of from about four to about nine inches. Such dimensions,with foamed perlite cement in the panel body 40, permit benefits offour-hour fire resistance, mold proof, and termite-proof.

A panel member 30 typically has a height of at least two feet and alength of at least about four feet, although vertical and longitudinalextents are adaptable without departing from the scope of the invention.A typical standard panel member is about ten feet long and from seven toten feet high, with a preferred height of around eight feet. Panelmembers exceeding dimensions of 16 feet by 16 feet are not recommended.Panel members according to this disclosure have a minimum crushresistance rating of 50 psi, and a minimum lateral shear load rating of20 psf. The maximum load rating of a panel member 30 on edge isapproximately 10,000 pounds per linear foot.

FIGS. 7 and 9 indicate how the concepts of this system and method ofthis may be utilized to erect a two-story building. The lower panelmember 30 is completed and installed upon the footing substantially asdescribed hereinabove. In a two-story construction, the tie rods 46extend well beyond the upper ends 43 of the bottom panel's conduits 42,and indeed project well above the first-story bond beam 68, as seen inFIG. 7. The bottom 38 of the frame 32′ for the second story is placedupon the ground story's upper bond beam 68. The lower tie rods 46 extendinto the interior of the second story conduits 42. Second-story tie rods46′ within the second story conduits 42′ are secured end-to-end with thelower story tie rods 46 by means of, for example, a coupling nut 65. Theprocess described above for the erection of the ground story can then berepeated essentially step-by-step to provide the second story of thedwelling, including the placement of any desired type of roof components62′. FIGS. 7 and 9 show that the system of the invention accommodates avariety of architectural features and flourishes, such as parapet walls67.

It is immediately appreciated that the method and system are well-suitedfor fabrication in modules. A collection of modular panel members ofselected sizes and configurations may be mass-produced and cataloged foruse in erecting mass-manufactured buildings. A collected kit of modularcomponents according to this system may be bulk shipped to a buildingsite, where a structure of a selected design is then assembled accordingthe particular kit's fixed plan.

The panel frames 32 and reinforcing conduits 42 may be manufacturedseparately to a standard panel member dimension with a minimum length offour feet and a minimum height of two feet. The frames can then bemodified to fit blueprints for specific structures, including but notlimited to electrical, plumbing, windows, and doors.

Assembled frames are filled with the foamed cementitious materialdescribed above. Poured panels 30 are cured in ambient air at atemperature preferably between about 50° F. and 110° F. for a minimum ofabout four days. Thereafter, individual panel members may be moved ontoflatbed trailers or train cars, and may be so loaded as to be unloadedin the appropriate order of assembly at a job site. Panel members maycontinue curing in transit to the building site, or during storage,until such time as they are delivered, erected, and installed at theproject site. Panel members are unloaded at the building site anderected using a crane, forklift, or the like.

The footing 20 according to the foregoing descriptions is placed in theground according to project site design specifications, and allowed tocure prior to erection of any panel members thereon. Once a kit orrequisite collection of selected panel members 30 and roof deck 62 andauxiliary components are delivered to the site, they are erected,bolted, and welded. The plumbing is stubbed and the wiring pulled. Thedeck 62 is installed, and the monolithic concrete pour filling thechannels 22, reinforcing conduits 42, and defining the roof cap 63 withintegral bond beam is accomplished using conventional transit-mix trucksand mix pumping as needed. The basic assembly of a residential structureof around 3,500 square feet may be accomplished in only a few days.

It should be appreciated that buildings according to the invention areintended to be permanent structures. However, for buildings that are tobe portable, the monolithic final (roof) concrete pour is not done, sothat the panel connecting welds can be cut, the panel componentsunbolted, and the building relocated elsewhere.

The speed with which the present building system can be manufactured,delivered, and installed offers tremendous opportunities for contractorsto reduce the cost of delays relating to standard framing and drywall.The system and method additionally provides increased value tohomeowners through a building system that is fire resistant, mold proof,termite proof, and is up to forty percent more energy efficient thancustomary two-by-six lumber framed structures. Moreover, the advantagesof this building system can be realized at costs equal to or less thanthat of conventional building materials and practices.

Although the invention has been described in detail with particularreference to these preferred embodiments, other embodiments can achievethe same results. Variations and modifications of the present inventionwill be obvious to those skilled in the art and it is intended to coverin the appended claims all such modifications and equivalents.

1. A method for erecting a structure comprising the steps of: disposinga reinforced concrete footing, comprising the steps of: defining along asubstantial length of the footing a longitudinal channel in a topsurface thereof; and disposing an anchor bar within and along thelongitudinal channel and securing the anchor bar to the footing;preparing a panel member, comprising the steps of: assembling a frame todefine at least a top, two ends, and a bottom of the panel; situating atleast one conduit within the frame, extending from an upper conduit endpenetrating the top of the frame to a lower conduit end penetrating thebottom of the frame to provide fluid communication between the frame topand frame bottom; forming within the frame a foamed cementitious panelbody, the panel body having two sides and the frame defining the bodyperimeter; placing the panel member upon the footing and proximate tothe anchor bar; securing the panel member to the anchor bar; and fillingthe at least one conduit with concrete.
 2. The method of claim 1 whereinthe step of defining a longitudinal channel comprises laying a metalC-channel in the top surface of the footing prior to curing the footing.3. The method of claim 1 wherein the step of securing the anchor barcomprises the steps of integrating with the footing a securing boltextending into the longitudinal channel.
 4. The method of claim 1wherein the step of assembling a frame comprises contiguouslyinterconnecting segments of steel C-channel.
 5. The method of claim 1wherein the step of placing the panel member upon the footing comprises:registering the panel member bottom with the longitudinal channel; andplacing the lower conduit end in fluid communication with thelongitudinal channel.
 6. The method of claim 5 wherein the step ofsecuring the panel member to the anchor bar comprises: situating rodmeans along the interior length of the at least one conduit; connectingthe lower end of the rod means to the anchor bar; and engaging the upperend of the rod means with the upper conduit end.
 7. The method of claim6 wherein the step of connecting the lower end of the rod meanscomprises: providing a hook means on the lower end of the rod means; andengaging the hook means around the anchor bar.
 8. The method of claim 7wherein the step of engaging the hook means around the anchor barcomprises engaging the hook means at substantially any location alongthe length of the anchor bar.
 9. The method of claim 5 wherein the stepof filling the at least one conduit with concrete comprises permittingwet concrete to flow from the lower conduit end into the longitudinalchannel.
 10. The method of claim 4 wherein the step of situating atleast one conduit member comprises welding a steel pipe to at least thetop steel C-channel member.